UNFCCC-Climate Technology Centre and Network (CTCN ...

UNFCCC-Climate Technology Centre and Network (CTCN)

Technology Assistance Project

Feasibility Study on Introducing a Hybrid GHG Reduction Technology for the

Cement Sector in South Africa

Research Institute of Innovative Technology for the Earth (RITE)

February 2017

1. “New Earth 21”： Earth Regeneration Plan

1990 2050 2100

proposed by Japanese government in 1990 G7 summit

Tota

l G

HG

em

issi

ons Energy conservation

If no measures are taken

If “New Earth 21” is effectively implemented

Next generation technologies

Global Climate Change

Energy Conservation

Clean Energy

Role of RITE

Innovative technology

Expansion of CO2 sinks

Global rise in temperature Rise in sea-revel

2 Copyright ©2017 RITE All Rights Reserved

1.1 Profile of RITE

Objective : R&D of industrial technologies that contribute Objective : to the conservation of the global environment and

the progress of the world economy

Establishment : July 1990 (Supported by MITI, local Establishment governments, academic circles and industries)

Location : Kansai Science City

Activities : Development of innovative environmental technology Activities : Expansion of CO2 sinks

Staffs : 168 (April 2015)

Annual budget : Approx. 2.4 billion JPY (20M US$)


CCS: Carbon dioxide

Capture and Storage • Technologies for separating/capturing

CO2 emissions from major emitters •Geological and ocean storage or sequestration of CO2

Proposal of modeling-based

global warming strategies

for the near to distant

future

1.2 Focuses of RITE Key Activities

Innovative bio-refinery

technology • Production of bio-fuels from cellulose • Production of chemicals from cellulose • Technology for large-scale CO2 fixation

using high-performance plants

Development of

Hydrogen Energy

Carrier


1.3 Focuses of RITE Key Activities

• Technological development for preventing global warming

◆CCS: Carbon dioxide Capture and Storage ・Technologies for separating/capturing CO2 emissions from major emitters ・Geological and ocean storage/sequestration of CO2

◆Innovative bio-refinery technology ・Production of bio-fuels from cellulose ・Production of chemicals from cellulose ・Technology for large-scale CO2 fixation using high- performance plants

• Support policymaking by Japan and other countries

◆ Proposal of modeling-based global warming strategies for the near to distant future


CTCN was initiated at COP16(Cancun) and the network was established at COP18 (Doha)

Hosted by UNEP and UNIDO, the CTCN is the UNFCCC’s technology mechanism

(i)to provide technical assistance(TA) to accelerate the technology transfer;

(ii)to disseminate information and knowledge on climate technologies;

and

(iii) to become a hub of collaboration among climate technology stakeholders. https://www.ctc-n.org/

2. Climate Technology Centre & Network（CTCN)


https://www.ctc-n.org/



Technology Information Clearing House (TT:Clear)

290 proposed projects

2.1 CTCN and Network

Consortium Partner

AIT (Thailand) Bariloche Foundation (Argentina) CSIR (South Africa) GIZ (Germany) ECN (Netherland) TERI (India) Enda-TM (Senegal) NREL (USA) CATIE (Costa Rica) UNEP（Kenya) UNIDO(Austria) ICRAF(Kenya) UNEP-DTU (Denmark)

Mini Project

Finance Support

GCF & GEF

TEC (Technology

Executive

Committee)

COP

Relevant organizations or

association in developing

countries (e.g. ACMP)

21 members including 16 government representatives

Guidance

Technology Assistance (TA)

TA Request

CTC Network Member

245 organizations including RITE

Full Size Project

Guidance

Guidance

NDE (109 countries)

Consulting

Advisory Group

Copyright ©2017 RITE All Rights Reserved 7

CTCN (UNEP-UNIDO)

2.2 TA Project Outline 1. Title : • Substantial GHG emissions reduction in the cement industry by

using waste heat recovery combined with mineral carbon capture and utilization

2. Purpose: • To estimate significant GHG emissions reduction from the cement sector by using carbonation technique with waste concretes and concrete sludge

• To find appropriate and marketable means to reuse byproducts from the carbonation process and estimate GHG abatement cost

3. FS terms: One Year (December 28,2016 - December 28, 2017)

4. Members:

• RITE (CTC network member, Japan) • ACMP( key representative, RSA) • Local Partners: ACMP member company/ies, Concrete product

manufacturer(s), DEA (Chemical and Waste Branch/Climate Change Branch) and South Africa National Energy Department Institute (SANEDI)

• MCC Expert: Tohoku University • Cement & Concrete Experts: Taiheiyo Engineering Corporation

and NIPPON Concrete Industries Co., Ltd. • Finance Expert: Mitsubishi UFJ Morgan Stanley Securities Co., Ltd.


Concrete Wastes

Concrete Sludge

Waste Heat Recovery

or

MCC&U plant (reactor)

CaCO3

Remediation Agents: Adsorbents/Neutralizer

Reuse as construction materials, painting, glass, ceramics, paper, rubber, resin, asphalt filler, food, pharmaceutical , colorant, etc.

Removal of toxic materials from wastewater and soil, e.g. phosphorus and arsenic and reuse the materials

Industrial Wastes containing Alkali Earth Metal (e.g.

Blast Furnace Slugs, etc.)

or

9

CO2-rich Exhaust Gas from Cement Kiln

Step A CTCN Technical Assistance

Resource Efficiency

Resource Efficiency

Resource Efficiency

GHG reduction due to Carbon mineralization

Hybrid low carbon technology

Energy Conservation

2.3 Technology Concept : Waste Heat Recovery & Mineral Carbon Capture and Utilization(MCC&U)

Copyright ©2017 RITE All Rights Reserved

2.4 Image of Overall Project Flow This study will examine a possibility of the hybrid low carbon technology in the CTCN TA.

by a National Designated

Authority (NDA)

Copyright ©2017 RITE All Rights Reserved 10

11

Expert Group

•Taiheiyo Engineering Corporation (TEC)

•Tohoku University (TU)

•Nippon Concrete Industries Co., Ltd. (NC)

•Mitsubishi UFJ Morgan Stanley Securities, Co., Ltd.

(MUMSS)

CTCN/UNIDO

Subcontract

• ACMP member company/ies

• Concrete Product Manufacturer(s)

• Consultant(s)/ Institute(s)

ACMP（Partner）

Grant of FS Fund

RITE (CTC network member)

Project Manager : Cement/Concrete Expert

Internal Quality Assurance

2.5 TA Project Framework

RSA NDE

Communication

Communication & Support

DEA SANEDI


3. WHR: Waste Heat Recovery Power Generation

– Steam is generated at waste heat boilers by utilizing waste heat from preheater and clinker cooler in cement manufacturing system.

– Generated steam is introduced to turbine generator to generate electricity.

– Around 1/3 of necessary power can be generated by WHR.


Source: Taiheiyo engineering Corporation

Heat utilization in Cement Plant (Rotary kiln)

Input Output

Heat from material/air4%

Clinker burning reaction 53%

Drying raw material/coal 9%

Exhaust gas heat 9%

Clinker heat 3%

Others 8%

Recovered by WHR power generation 18%

Combustion of fuel 96%

Effective Energy 80%

Exhausted Energy 20%

18% of input energy can be utilized with WHR

13

3.1 Heat efficiency of WHR

Copyright ©2017 RITE All Rights Reserved Source: Taiheiyo engineering Corporation

Indirect CO2 Emissions

Direct CO2 Emissions

3.2 CO2 emissions before/after WHR

with WHR

Calcining

Fuel Burning

Purchased Electricity

Calcining

Fuel Burning

CO2 emissions reduction

CO

2 Em

issions

Purchased Electricity



• Substantial CO2 emissions reduction can be achieved

• Considerable amount of power can be utilized for the manufacturing

• Electricity supply shortage can be relieved

• Help the South African economy to develop while protecting environment

15

3.3 Features of WHR on Cement Manufacturing



16

4. Why MCC&U ?

Issue

Solution Mineral Carbon Capture

(MCC)

Marketable by-products

（Utilization）

MCC&U

CO2

Industrial wastes (containing calcium and magnesium)

Copyright ©2017 RITE All Rights Reserved Source: Nippon Concrete Industries Co., Ltd.

17

4.1 Information: Treatment of Industrial Waste

Before concrete sludge is solidified, solid cake is

separated from the sludge. “Solid cake” is disposed

to landfill sites it’s while the “liquid portion” is

neutralized and then discharged to sewage or river.

● Treatment cost is very expensive （50 ～100 USD/t）

Filtration Storage

with agitation

Neutralization

Generation

from formwork Sewage

or River

Landfil

l

Site


Photo: Nippon Concrete Industries Co., Ltd.

18

4.2 Carbon Mineralization

Ca and Mg from Concrete Sludge + CO2 →

Carbonates (CaCO3, MgCO3)

Advantages:

1.Huge potential for sequestration

2.Stable sequestration

3.Safety reaction process


19

4.3 Potential Alkaline Earth Metals from Wastes

0 Availability [tonne]

Reactivity with CO2 (Carbonation

rate)

Concrete sludge

Demolished waste

concrete

Alkali rocks

Blast furnace slag

Possible ?

Copyright ©2017 RITE All Rights Reserved Source: Tohoku University

20

4.4 Five Features of MCC&U

Innovative, yet easy to operate and safe to apply even in developing countries

Possible for technology diffusion in developing countries

Expecting substantial greenhouse gas emissions reduction by using concrete sludge and demolished waste concretes

Small operation costs (=Total cost for the MCC operation - Sales value of by-products )

High resource efficiency


Concrete Wastes

Concrete Sludge

Waste Heat Recovery

or


CaCO3






or

21



Resource Efficiency

Resource Efficiency

Resource Efficiency



Energy Conservation

5. MCC: GHG Emissions Reduction


22

5.1 Process Flow of Carbon Mineralization Applied in Japan Utilizing Concrete Sludge


23

- Bench scale plant (2009-)

2 Reactors (1 m3) + 2 Storage tanks (1 m3)

equipped with pH meters, level meters, thermo meters,

concentration meter for CO2, pressure gauge for flue gas, etc.

- Business operation plant (2013-)

Single Reactor (40 m3)

5.2 Development of MCC&U Plants in Japan

Installation site:

Kawashima 2nd factory of Nippon Concrete Industries Co. Ltd.

which produces concrete poles by centrifugal molding



24

5.3 Outlook of the bench-scale plant

Calcium Extraction reactor

Storage tank 1

CaCO3 precipitation reactor

Storage tank 2

Completed

in June 2009

Stack from boiler

for high-temperature

curing of concrete pole



25

5.4 Photos of Ca extraction experiments

Concrete sludge introduction During agitation *

After stopping

agitation

After decantation

•Calcium is extracted from

concrete sludge into a liquid

phase.

Copyright ©2017 RITE All Rights Reserved Photo: Nippon Concrete Industries Co., Ltd.

26

5.5 Photos of CaCO3 precipitation experiments

Before CO2 bubbling After CO2 bubbling

Become clouded (After 1 min of CO2 injection) *

Crystal

growth (After

3 min)

Gravitational

sedimentation

(After bubbling)

• Due to the CaCO3 precipitation

Copyright ©2017 RITE All Rights Reserved Photo: Nippon Concrete Industries Co., Ltd.

27

5.6 CaCO3 Produced from the Process

* image

● Purity: 99 wt% ～

Crystal shape: Calcite

Particle size: 1 ～ 20 µm

（Volume based laser scattering diameter）

● The produced CaCO3 can be reused as feedstock for

non-energy use (example: choke, white line for

ground.)


28

5.7 Estimation of Carbon Captured Volume


30

5.9 Various Waste vs. Carbon Captured Potentials


Concrete Wastes

Concrete Sludge

Waste Heat Recovery

or


CaCO3






or

31



Resource Efficiency

Resource Efficiency

Resource Efficiency



Energy Conservation

6. U: Sales of Marketable By-Products


32

6.1 By-Product (1): CaCO3

Purity of the produced CaCO3 is over 97 wt%


33

6.2 Application of CaCO3

Table(a). Applications and its functions

Fraction

[wt%]

Paper 115 58.7

Rubber 23 11.7

Resin 18 9.2

Paint 8 4.1

Others 14 7.1

Export 18 9.2

Paper 73 34.8

Rubber 55 26.2

Resin 44 21.0

Paint 10 4.8

Others 9 4.2

Export 19 9.0

ProductSelling volume (2003)

[103t]

Standard

product

colloidal

product

Light

CaCO3

Table(b). Application and selling volume

Application Function

PlasticImproving strength, stability, mobility

and dispersibility and lowering costs

Rubber Improving workability and lowering costs

PaintAdjusting viscosity, paint workability

and joint searing

Paper

(filter)

Improving storage stability (alkalinize) and

lowering costs

Paper

(coating)Improving printing quality

AgricultureApplicable to agents for improving water-

solubility of pesticide and soil conditioner


34

6.3 By-Product (2): PAdeCS

Feature of PAdeCS

1. Possible particle size adjustment

2. Decontamination agent （example:

phosphorus and arsenic removal agent,

neutralizer, etc.）

3. Low costs compared to

conventional products

Effective as phosphorus removal agent applied to:

• Small-scale purification systems

• Rice washing wastewater rich in phosphorus

(under consideration)


Source: Nippon Concrete Industries Co., Ltd.

35

6.4 Business Operation Plant (since 2013)

One of the first pilot-scale plants of a mineral carbonation

process using alkali wastes.

Ca Extraction

reactor (2000

t/year, 30 m3)

Filter press CaCO3

precipitation

reactor (40 m3)

Crusher


Photos & Source : Nippon Concrete Industries Co., Ltd.

37

6.6 Mass flow of the plant

Concrete Sludge

Concrete Sludge

Water

CO2 from

Boiler waste gas

Calcium

Extraction

reactor

Filter

press

Filtrate

CaCO3

Crystallization

Reactor

Sludge cake

PAdeCS

CaCO3

Filter

press

Discharge

Neutralization

by Sulfuric acid Discharge

10 t 5 t

5 t

10 t

10 t

20 t 5 t

15 t

450 kg CO2

CO2 release

14 t

1 t

about

5kg

Conventional treatment process

Business operation plant

Solid part : Liquid portion

= 1:1


38

Research item/ActivityJan. - Mar. Apr.- June July – Sep. Oct. – Dec.

Sandton & Sites Sandton & Sites Sandton Sandton & Pretoria

Activity 1. Identification and testing of the available alkali-rich industrial wastes and assessment of the MCC reactionActivity 1.1Activity 1.2Activity 1.3

Activity 2. Assessment of the domestic market for the by-productsActivity 2.1Activity 2.2

Activity 3. Estimation of the GHG emissions reduction potential of WHR and MCC &U for the cement sectorActivity 3.1 & Activity 3.2Activity 3.3 & Activity 3.4

Activity 4 –Development of a business plan and project implementation recommendationsActivity 4.1 & Activity 4.2Activity 4.3 & Activity 4.4

Activity 5. Stakeholder meetings

Activity 5.1Project introduction and preparation<February 2>

Activity 5.2Report on 1.1 & 1.2 and preparation for 2 & 3

Activity 5.3Report on 1.2 + interim report on 2.1, 2.2, 3.1 &3.2

Activity 5.4Disseminate the findings of the business plan and the hybrid low carbon technology

Submission of Report to UNIDO Inception Report

Progress Report

Final Activity Report

7. Work Plan


39

8. Post CTCN


Step B Image of proposed mobile bench-scale MCC&U reactor

Step C WHR equipped with a stationary MCC&U reactor

Source: Nippon Concrete Industries Co., Ltd.

Thank you for your

attention !

Contact to [email protected]

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